Lighting assembly



Aug. 18, 1942. A U 2,293,284

LIGHTING ASSEMBLY Filed April 25, 1938 Sheets-Sheet l g H V l I 9 I W 27 70 a a -2 2w 2 a 5;; 5 4 a J & 34 I /7 from Er 1942- B. D. EMANUEL LIGHTING ASSEMBLY Filed April 25, 1938 3 Sheets-Sheet 2 Aug. 18, 194 B.-D. EMANUEL LIGHTING ASSEMBLY Filed April 25, 1938 3 Sheets-Sheet 3 Patented 18, 1942 iJNlTED STTES FFECE 4 Claims.

This invention relates to improvements in lighting assemblies, and has particular relation to structures of this type designed for portable service, th'e specific form of structure being in the field of portable structures generally termed flash-lights.

Flashlight structures have been known for many years and have reached a commercial development of world-wide extentthey are generally considered as a necessity in the varied activities of human life. The commercial development, however, has been based generally on structures employing dry-cell batteries, the latter offering a ready source for the small current values used in the operation of such lights; batteries for this service can be of small dimensions individually, and can be utilized in series, so that itis possible to readily utilize them within the small dimension containers which have become the standard for structures of this type. The batteries, being small, and of wide-spread use, can be produced at low cost.

However, flashlights utilizing the dry-cell batteries have certain disadvantages. Since each battery is of limited life as a source of supply or" currentits value decreases with use from maximum when first installed to the time when it no longer will provide sufficient current value for service of the lamp-the efiiciency of the lamp must depend upon substitution of batteries, the frequency of substitution depending upon the frequency with which the light is used; after a limited number of hours, the candlepower of the lamp becomes insufiicient for efficient service, and

unless substitution of battery is provided, the

lamp becomes useless. Where the light is in frequent service-in inspection service, for instancethe user is required to carry surplus batteries to meet possible emergencies of this kind. (Ether disadvantages are well-known, but the disadvantages have been accepted by th'e public due to the fact that no efficient substitute for this type of battery has been developed.

The substitution of a rechargeable battery for the dry-cell battery in this particular field has been a subject of experimentation for many years, but theoretical possibilities have failed to prove satisfactory, due to a number of factors inherently present in the form of problems which must be met. For instance, the small dimensions of the battery space provide a difficulty; the conditions set up during re-charging require a battery capable of meeting these-in presence of the fact that the light, in service, is used in varied positions; the re-charging action is another factor requiring consideration, etc. To illustrate some of the conditions, a few illustrations are given:

In the development of the miners lamp field, such substitution has been employed. Initially, a separate batt ry of considerable size was carried by the user with flexible wire connections to the lamp, thus making it possible to provide a battery which would remain active for many hours, and permit of substitution of one battery for another during recharging. Due to the cumbersome arrangement thus set up, a system was developed which utilized small batteries capable of being carried by the lamp itself, but in which the life of the battery charge was slightly greater than that which would, be required for a single period of service by the user, at which time the lamp was returned to a charging station where the batteries of all the lamps used were removed and re-charged during the off-duty period, or recharged batteries were substituted, if necessary, the charging station being equipped to permit concurrent charging of a plurality of batteries. Efficient service is possible under these ccndi tions, but is made possible only by the fact that the large number of lamps in daily use will warrant the establishment of a charging station such as this with the attendance necessary to make the station serviceable.

Obviously, such procedure is impracticable for individual users of flashlights. A charging station of this type would not be justified for the individual service, and time in attendance during charging could not be spared. Unless accurate records of use were kept need for charging would be unknown and battery depletion could occur at undesired times. Nor would a neighborhood central station be warranted, since the service to be rendered would be somewhat infrequent and the expense or maintaining the station would not be justified. Other possible objections are apparent, but these are sufficient to indicate why the miner lamp development has not been translated into the commercial flashlight fieldand the limitation of that field to the drycell battery operation.

Other structures contemplated have been designedto be connected up to the charging circuits of motor vehicles, and thus be capable of being charged when the unit is not in portable service. Zhese, however, are more or less theoretical in type since they have not, although designed for special types of service, developed commercially, probably due to the fact that they fail to meet certain inherent conditions set up in charging; in addition, they all rest upon the use of batteries of comparatively large size due to' the fact that since charging is continuous, provision must be made to prevent overcharging, and this is done by the use of a large battery-otherwise the charging must be had under the control of the user, thus setting up conditions of requiring the driver to divide his attention between driving and charging. Obviously, the theoretical teachings of these structures have been valueless in the direction of flashlight operation, since the available battery space is relatively small and a battery having dimensions for such space would be rapidly overcharged and rendered useless.

The nearest approach to a feasible structure of a portable flashlight operating with a rechargeable battery is that presented in the patent to Blake, No. 1,999,079, April 23, 1935, (assigned to present applicant), in which the battery is contained within the casing of the light and is charged in situ. The disclosure of the patent reaches in the direction of the substitution of the rechargeable battery for the dry-cell battery in this particular field under conditions in which individual usage can form the basis of action. However, the disclosure is not completely satisfactory, due to the fact that the battery showing is more or less conventional, and therefore fails to present a solution to a number of the problems found to be present in an attempt to meet the conditions for which the structure is designed.

One of these problems is set up during the charging operation. During this period itis inevitable that gases will be developed within the battery, and these must be released. Where the battery is removed for charging, as in the miner's lamp, the battery may have an opening for such release and this can be closed before the battery is restored, thus preventing loss of the electrolytic fluid. Where, however, the battery is charged in situ, the gas release means must remain as a permanent part of the battery assembly, and this sets up the conditions of a possible leakage point of fluid, due to the fact that the light, in use, is placed at all angles, thus opening up the possibility of leakage conditions. The Blake disclosure does not present a specific solution to this problemdue to the use of a special form of battery disclosed elsewhere but not patented; experiments have shown that the Blake battery contemplated is not a wholly acceptable solution to this problem when the flashlight is subjected to many of the conditions of service. I

The present invention thus reaches into the special field for which the Blake disclosure was designed, but through the development of a special type of battery and a simplification of the structure, as well as the addition of a particular form of charging structure, permits the desired substitution of re-chargeable for dry-cell batteries in this particular field of flash-light service, doing this through solution of a number of problems which remained unsolved in the Blake disclosure.

The present invention therefore has for its principal object the production of a lighting assembly of this type in which the flash-light is capable of its varied service conditions; in which the battery is re-chargeable without requiring attention-by simply positioning it on its support when not in use; in which the light can be maintained in service over extended periods under maximum efiiciency conditions, and yet be restored to maximum value conditions during periods when the light is not in service; in which the life of the battery is extensive but in which the battery can be replaced in simple manner; in which the charging cost is minimum and provided without damage to the battery, thus greatly reducing the maintenance cost of the lighting unit. Other objects are the production of a battery unit of overall dimensions readily received within the dimensions of the standard flash-light units, and yet provide for eflicient current supply for the lighting bulb; which can be readily recharged without damage while in its normal position within the lighting unit; the formation of a battery with a special type of plate assembly of maximum efiiciency; the provision of an eflicient venting unit with the latter providing one of the battery terminals. In addition, the invention contemplates the production of a lighting assembly of this type which can serve as a substitute for the commercial dry-cell flash-light service; which can be produced at low cost; which is simple and efiicient in operation; and in which service maintenance costs are extremely low.

To these and other ends, therefore, the nature of which will be readily understood as the invention is hereinafter disclosed, said invention consists in the improved construction and combination of parts hereinafter more particularly described, illustrated in the accompanying drawings, and more particularly set forth in the appended claims.

In the accompanying drawings, in which similar reference characters indicate similar parts in each of the views- Figure 1 is a view in front elevation of a lighting assembly of the general type of the present invention, the flashlight being positioned on the charging bracket,

Figure 2 is a vertical'section taken on line 22 of Figure l, with the battery shown in elevation,

Figure 3 is a fragmentary longitudinal section taken on line 3-3 of Figure 2,

Figure 4 is a cross-sectional view, taken on line 44 of Figure 1,

Figure 5 is a view of one form of battery, the battery casing being shown in longitudinal section with the internal non-liquid content shown in elevation,

Figure 6 is a view of the battery of Figure 5, with the internal non-liquid content also in section longitudinally of the battery,

Figures 7 and 8'are detail cross-sections taken on lines 1'! and 8'8 respectively of Figure 6,

Figure 9 is a detail longitudinal section of a preferred form of venting unit terminal,

Figures 10 and 11 are views corresponding to Figur-es'5 and 6, respectively, but illustrating a different type of plate assemblage,

Figures 12 and 13 are detail cross-sectional views taken respectively on lines I2-l2 and I 3-I3 of Figure 10,

Figure 14 is a fragmentary longitudinal section taken on line 144s of Figure 10.

The lighting assembly of the present invention comprises a flashlight unit and a charging bracket unit, the latter being designed to form the support for the flashlight unit when the latter unit is not being put into service. For instance, the light might be carried about ready for activity when neededinspection service is an exampleand used intermittently during such period, thus making the period a service period; at other times, the invention contemplates the positioning of the light unit on the charging unit. This association of the two units is designed for the purpose of maintaining the battery of the lighting unit in charged status as far as possible. The battery of the lighting unit is designed to permit continuous service for a number of hours, a time length that is considerably greater than normal flashlight service generally contemplates, so that it is generally the case that complete battery depletion is not actually present at the end of the service period. If, therefore, the lighting unit is placed on the charging unit at the close of the service period, recharging can take place until a succeeding service period requires lighting unit service, thus replenishing the battery without requiring any particular attention on the part of the user. The battery depletion during a service period is generally so small that a very low charging rate can be employed for re-charging without likelihood of overcharging the battery over extended periods of idleness.

To permit a result such as this, it is essential that both units have particular characteristics. For instance, the charging unit must be capable of providing the charging action whenever the lighting unit is in position, and yet do this without overcharging the battery. This is obtained by arranging the charging unit in such way that in positionin the lighting unit a charging circuit is automatically established; by positioning a high resistance in that circuit, the rate is maintained very low. For the purpose of illustration, one

service of the lighting unit is that of a trouble light in motor vehicle service; a direct-current storage battery of six volts is generally used with motor-vehicle service, and this is connected up to the charging unit, with a resistance of 50 or 150 ohms in the line, the resistance value depending on the extent of use of the lighting unitthe smaller value being used where the unit is in daily use and the higher value where the unit use is only occasional.

Not only must the charging unit be arranged to provide the result, but the lighting unit must be arranged to meet the conditions set up through the fact that re-charging of battery is to be had. Not only must the battery be capable of functioning as the power source for the lamp of the unit over extended periods, but must also be capable of being re-charged under conditions such as above. Ebullition in the battery with evolvement of gas takes place during recharging, and this must be permitted during the charging period, and yet prevent the escape of electrolyte during use of the lighting unit under all conditions of service. While this condition is readily secured Where space conditions are more or less unlimited and where the battery is of the one-position type, the fact that the lighting unit is itself of the flashlight type and must be capable of flashlightservice and is of dimensions similar to commercial flashlights of the dry-cell type, it is obvious that the limited space conditions present difliculties such as to require special characteristics in the elements of the lighting unit itself.

Referring to Figs. 1 to 4, the lighting unit includes an elongated tubular metallic casing 20 of desired length, the casing having its opposite ends threaded to receive the lamp section 2| at one end and the closure 22 at the opposite end. The lamp section includes the usual casing, lamp, reflector, lens, etc. with the usual arrangement of terminals, one of which includes the connection of, the lamp socket with the casing; the connections to one of the lamp or bulb terminals include a make and break device, thus conforming to the general practice present in flashlights utilizing dry cell batteries. However, certain modifications are es- 5 be of any desired form, the form shown being more or less illustrative, being based upon one type of commercial flash-light structure of the dry cell type. In this showing, the lamp socket, indicated at Ma, is shown as carried by a diaphragm 20a, supported by casing 20, the socket being insulated from the diaphragm. The diaphragm also carries a terminal 23, having a lip 23a, this terminal having contact with the socket, but insulated from the diaphragm and from a bridge member 24 and terminal 2 5, also carried by the diaphragm but insulated therefrom, terminal 25 being adapted to contact the usual teat contact of the lamp bulb, while the socket reaches to the opposite terminal of the bulb as is usual. Casing 20 is shown as carrying a slidable make and break element 26, the latter including a spring arm 260, having a lip 26b adapted to be moved into and out of contact with lip 23a by movements of a suitable actuator 26c. Assuming that bridge member 24 is contacting the negative terminal of a battery, with the casing contacting the positive terminal of the battery, it will be understood that when lips 23a and 2% are in contact engagement, a circuit between battery and bulb will be established; when the lips are separated, this circuit is broken between the battery positive terminal and the lamp socket, leaving the battery negative terminal in circuitmake relation with the terminal 25.

This arrangement of lamp section is adapted for service in the assemblage of the present invention, by utilizing a charging terminal 21 in interposed relation between the bridge member 24 and the negative battery terminal, the charging terminal being carried internally of and insulated from the casing, and having an angular portion 21a which extends beneath the bridge 24, remaining in permanent contact therewith; the negative battery terminal contacts with the angular portion 21a and the latter thus forms a part of the lamp bulb circuit whenever lips 23a and 261) are in contact engagement; the bulb circuit is broken when the lips are out of engagement, thus rendering the bridge member 24 inactive, but retaining the charging terminal 21 in contact engagement with the negative battery terminal; if, therefore, terminal 2'! be operatively connected with a charging circuit, the latter circuit will be completed through the battery, leaving the bulb inactive due to the break in the bulb circuit at the lips 23a and 26b.

Charging terminal 2'! is secured to the interior of casing 20 and insulated therefrom, the casing carrying an opening 202) overlying terminal 21, the opening receiving an insulating bushing 28, the opening of which permits of the entrance of a contactpresently described-carried by the lamp supporting unit. During charging, the bulb circuit is retained broken at lips 23a and 26b, thus preventing bulb activity during charging and preventing short-circuiting of the charging circuit through the bulb.

The charging unit, shown in detail in Figs. 1 to 4, is in the form of an angular bracket 30, secured at a desired point by suitable means, the base member 30a projecting forwardly and carrying an insulating pad 33!) upon which the flashlight rests, the preferred arrangement placing the bulb end of the flashlight as the lower end during charging, as indicated in Figs. 1 and 2, the flashlight thus being inverted during this period. Th'ebracket carries a pair of supporting clips 35c insulated from the bracket, as indicated, these clips receiving the body portion of the flashlight. The bracket basemembe'r' 39a carries a pair of depending clamping clips 32 insulated from the base and adapted to receive and support a removable resistance element 33, of de". sired resistance value; one end of the resistance has an operative connection with one of the charging battery terminals (not shown), the opposite end of the resistance being operatively connected with the lower of the two clips 39c, as by a connection E i-these connections may, if desired, reach to the clips 32 with the latter then engaging the opposite ends of the resistance element 33, thus permitting substitution of resistance elements without affecting the charging circuit connections with the charging battery.

The bracket opposite opening 201), carries a suitable contact adapted to engage terminal 2'! when the flashlight is in its charging position. The contact may be of suitable type, the drawing indicating a small casing 34 carried by the bracket and which supports a contact 55 yieldably supported by a spring 35 mounted within 3 support, the positive terminal of the battery being charged being reached through the lamp casing 253 from the lower clip 390. Contact 35, being yielding, can provide elficient engagement with the positioned terminal 2'! without affecting the latter within casing 29.

As pointed out above, the resistance value of the resistance element 33 may be as desired or found necessary. This element is designed to control the rate of charging of the battery to be charged; where the flash-light is being used infrequently, the rate of charging can be materially reduced with an assurance of efiicient action, while daily service of the light would require a higher charging rate. As examples, it may be stated that if the lamp is used daily, a preferred resistance value would be approximately 50 ohms; where the service is infrequent, the value may be increased, for instance, to 150 ohms; these values are illustrative only, and will depend upon the value of the charging source. If the charging is to be from an electric light circuit, an additional controlling device would be inserted in the connections as is usual in cases where the voltage is to be stepped down.

The battery employed is disclosed in the general types, these differing as to the structure of the plate assembly. In one type the plates extend transversely of the axis of the batteryin the other type the plates extend longitudinally of l the battery. Either type can be employed, but

because the transverse arrangement enables a largely increased plate surface, this particular type is preferred, and will first be described, this being disclosed in Figs. 5 to 9.

The battery casing 35' is tubular with one end closed, the opposite end being internally threaded to receive a threaded closure The casing and closure are formed of suitable material not affected by the electrolyte-hard rubber, or one of the materials of phenolic source may be em- 75 receiving the required internal structures and the electrolyte; hence the casing is of small diameter as compared with its length. The

closed end of the casing 35' is formed with an opening 351) for the passage of the negative terminal of the plate assembly, while the closure 35a is formed with an opening 35c for the passage of the positive terminal of the assembly. The openings are arranged leakage-proof with respect to the terminals; in practice, the batteries are arranged for service over an extended period-ayear for instanceof heavy-duty service, and are designed to be replaced, with the used battery returned to the manufacturer to be reconditioned for another period of service; consequently, the particular packing used will be such as will enable ready disassembly for reconditioning purposes.

The plate assembly in this type of battery is made up of a succession of grid plates 36, with each plate of skeleton type, and secured to opposing carriers 31, 38, located at opposite sides of the assembly, the arrangement being such that a plate is secured to one of the carriers while the two adjacent plates are secured to the other carrier, thus having alternate plates carried by the same carrier. The carriers extend longitudinally of the casing, and are generally similar within the zone of the plate assembly, the plates being arranged to permit this arrangement. For instance, each plate, while generally circular, has its contour at one side arranged with a'recess 36a, the inner wall of which carries a projection 3% designed to be secured in suitable manner within an opening of the carrier, as by soldering, the carrier extending into the recess; the plate is thus directly connected with such carrier. On the diametrically opposite side of the plate the latter is formed with a second recess 360 which is designed to receive the other carrier and its insulation. Hence, the grid plates may be uniform as to shape and be capable of being secured to either carrier, the latter having their openings arranged so that adjacent plates will be'secured to opposite carriers and yet have an assembly insulated relation with the carrier to which it is not connected, to thereby prevent undue stress on the securing projections 36b. The plate includes parallel bars 3611 to complete a grid eiTect, the plate being designed to receive the usual or any preferred paste that is employed in completing battery plates.

In the assembly shown, the carrier 31, with its plate assembly, forms the negative electrode, while the carrier 38, with its plate assembly, forms the positive electrode. In the arrangement, the general practice of having the outermost plates as parts of the negative electrode is preferably followed, the number of plates used thus being an uneven number. For the purpose of illustrating the dimensional characteristics of the battery, it may be stated that the space available for the plate assembly is approximately 1 inch in diameter by approximately 3 inches in length; the overall length of the battery is greater than this to permit accommodation for the vent assembly as presently described. Within the space referred to, the plate assembly, if the number of plates be 2|, the plate surface area will ap proximate 30 square inches.

The plate assembly is completed by the use of separators. These may be oi various materials. In this particular type of the battery, while the use of customary wood separators would be possible, the fact that the battery is practically a sealed battery with a definite amount of electrolyte would tend to render suchseparators of less value, due to the fact that when the lamp is inverted from the position shown in Figs. 1 and 2, for instance, the electrolyte would drain to the vent assembly portion of the battery, thus tending to drain the plate zone. Hence, with this type of battery, it is preferred to use separators having absorbent properties, such, for instance, as specially-treated asbestos sheet material, spun glass, Begrasse felt, and the like. Of the latter, either may be employed, the separators being comparatively thin and cut to fit within the spaces between adjacent plates. The asbestos material is the more absorbent, but its efiiciency will tend to deteriorate with use, so that the spun glass form a may be found more satisfactory for the service. With the absorbent separators, a sufiicient electrolyte will be trapped therein to maintain the light active over an extended period, even though the light be inverted. In the drawings the separators are indicated at 39.

The negative electrode 37 includes the end structure 31a, a portion of which is in the form of the central projection 311) which extends through the closed end of the battery and constitutes the negative terminal of the battery. The carrier 38 forms part of the positive electrode, and, as indicated in Fig. 6, this carrier extends for approximately the full length of the interior of the battery, thus extending a considerable distance above the battery plate-assembly zone. The upper end of carrier 38 forms a support for the vent assembly which will now be described.

During the charging period of a rechargeable battery, the action within the battery tends to set up certain changes therein, these including a tendency to ebullition of the liquid and development of gases; the extent of this will depend somewhat upon the rate of charging, etc., but the condition is present to at least some extent whenever the battery is being charged. To prevent damage to the battery, the latter is provided with a vent arrangement which will permit escape of such gases as may develop, during this period without carrying the electrolyte with them. The necessity for the use of a vent for the purpose has led to the development of various forms of venting structures. Under usual conditions, where the battery is removed to a charging station, the venting feature is readily taken care of, but it becomes more difficult where the battery is being charged in service position. In the latter case, provision is made to permit venting during charging, but must also prevent escape of electrolyte while in service. Generally this is not diflicult where the service retains the battery practically in the same position. Where, however, as is the case with the present service, the conditions are complicated by the fact that the battery assumes various positionsand may even be invertedthe problem is more difiicult, since, in such cases, the battery may be placed in a position where the free electrolyte may gravitate to the venting zone. Where the battery is permanently sealed, as in the present type, it becomes essential to provide for a permanent vent, and at the same time prevent electrolyte escape in service when the battery is inverted. The condition is met in the present invention by the following structure:

40 designates a hollow casing which is secured to the upper end of carrier 38. The opposite ends of casing 40 are formed with openings, the upper wall in Fig. 6 presenting the opening at this end in the form of a tubular extension 4| having a length to extend through closure 3512, the projecting portion constituting the positive terminal of the battery; to permit escape of gases, the terminal is shown as provided with kerfs Ala located on a diameter of the terminal. The opposite end wall of casing 40 has its opening carried by a nipple 42 which is designed to receive one end of an elongated tubular member 43 which depends from the casing and which serves as a gas outlet. Member 43 may be of suitable material-rubber tubing treated for the service may be emp10yeclthe free end of the tube having a restricted opening 43c, the dimensions of which will permit gas to enter but will prevent the passage of the electrolyte therethrough. The tube is preferably arranged as shown in Fig. 9, with a return bend or goose-neck characteristic, this placing the end carrying opening 43a as extending upwardly or away from the plate zone. The positioning may be obtained in any desired way, a simple arrangement being by the use of a clip 44, this permitting the presence of a slight space between opposite flights of the tube to permit passage of any electrolyte which may tend to gravitate from the exterior of casing 40.

As will be understood from Figs. 1 and 2, the flash-light is positioned with the bulb end down during charging, thus placing the plate zone of the battery as the lower end of the latter in these views, thus corresponding to the position of this zone in Figs. 5 and 6. In this position, the electrolyte is entirely within the plate zone, leaving the venting assembly wholly above the electrolyte surface; hence, any gases which may be evolved during charging, will pass out of the interior of the battery through opening 43a, member 43, casing 40 and terminal 4|. When the light is placed in service the bulb end may be pointed in any direction, the electrolyte tending to gravitate to the low point of the assembly, and hence may reach to the space occupied by the venting structure; when this occurs the electrolyte may cover opening 43a but the dimensions of the latter together with the particular shape of the tube 43 will prevent escape of the electrolyte.

Casing 40 provides an enlarged chamber to meet the possibility that gases may carry vapor with them in which case deposition of the vapor may take place on the walls of the chamber and gravitate downward into the return bend or goose-neck of the venting structure; the amount would be small even over the period of the expected life of the battery. Should this content not drain out of the tube 43, the gases during a charging period would force the entrained liquid back into the enlarged zone provided by this chamber of casing 43, and thus permit gas escape without loss of fluid. Any collection of electrolyte on the exterior of casing 43 will simply drain downward and drip on the venting structure when the light is placed in its charging position.

As will be understood, this structure provides an important advantage in that the venting structure not only serves as the vent, but also as the positive terminal of the battery, due to the fact that the venting structure is being carried by the carrier 38, itself a part of the positive electrode assembly. Consequently, there is no need for limiting the dimensions of the venting structure dueto the restricted space conditions present; in addition, the arrangement is greatly simplified through elimination of the need for providing for separate terminal and venting conditions within this end of the battery chamber.

The alternative form of plate assembly is shown in Figs. to 14, the battery, otherwise, being similar to that above described. In this form the plates extend longitudinally of the battery, and, as shown, are in the form of a pair of negative plates 45 spaced apart and connected at one end by a bridge 45a which carries the negative terminal 45b. The positive plate formation 35 is intermediate the two negative plates, the equivalent of. carrier 33 being formed integral with plate 46 and having the extension 46a attached to the casing it. The plates are separated by suitable spacers 47, which, in this form, may be the usual wood spacers, but are preferably of an absorbent material. If desired, a suitable holding el'ement'tt in the form of an insulated element, may be placed about the upper end zone of the plate assembly to retain the plates in proper relation in this zone.

In practice, the volume of electrolyte used with either form would provide for efiicient service. This volume would be such that when the light is inverted, the free electrolyte, while gravitating to the venting zone, would preferably not reach the level of opening d3athe venting assembly is so arranged that a sufiicient volume will be present without closing this opening when the battery is inverted. As pointed out, the battery is provided with the proper amount of electrolyte by the manufacturer, after which the battery is sealed and is marketed in such form. As marketed, the battery is designed to be efficient for a lengthy perioda year, for instance, under daily use conditionswhereupon it would be replaced, at nominal cost, by a new battery, the manufacturer then re-conditioning the used battery. With a battery serviceable for such lengthy period, the assemblage of flash-light and its charging support enables the user to have eificient service without the requirement of special attention, other than that of the substitution of one battery for another at the end of the period, and, at the same time, enables the manufacturer to give any guarantee for effective service, since the supply and replacement of battery is wholly under his control because of the sealed condition of the battery, and therefore subject to his control as to structure and electrolyte control.

As indicated, one of the important features lies in the fact that the positive terminal of the battery is a part of the venting assembly. Through combining the two essential features into the single formation, economy of space is provided Within the battery, through the fact that the venting assembly can be supported by the positive electrode instead of by the battery casing or vice versa. As a result, the venting assembly can be made of dimensions such as to enable an adequate supply of electrolyte to be employed Without liability of loss through the venting assembly, and an assurance of an adequate candle-power service for extended periods due to the fact that the plate zone is of adequate dimensions for the purpose. While these detailed features are more or less specific to the battery itself, they cooperate in the complete assembly through the fact that they permit of battery dimensions such as are usable within a flashlight casing of dimen ar to those aeeaess of the commercial dry-cell type designed for similar duty. v 7' For instance, in one of the forms of the present invention, the lamp bulb employed is of 1.5 volts, A amperage, and .7 candlepower; with a battery of the type described, tests have shown efficient operation for ten to fifteen hours of continuous use of the flash-light before the candlepower drop becomes effective. In the commercial drycell 'type' at least, two batteries in series are required, and these will not permit a similar length of continuous service without voltage and candlepower drop. In the latter form new batteries must be substituted; with the present invention, the flash-light is simply placed on its support assembly for re-charging.

Aside from the battery construction the lighting unit generally simulates the commercial flash-light of dry-cell type, so that the cost of production increase'over that type is mainly due to the battery and support structures. While the cost per assembly is thus greater for the present invention, the maintenance cost is but a fraction of that of the commercial type, with the advantage of being more eflicient in service. The initial battery cost is greater with the present invention, but being re-chargeable, its life exceeds that of many replacements of dry-cell batteries; replacement of batteries in the present invention would be at nominal cost due to the fact that batteries can be re-conditioned by t e manufacturer, making possible substitution of batteries at low cost. p

Either type of plate assembly disclosed herein may be employed. However, the form shown in Figs. 5 and 6 and 10 andll is preferred clue to the fact that it provides for relatively large plate surface exposure within the space'limitations. With the skeleton form of plate employed, the assembly can be readily produced, The details of the battery assemblies disclosed herein are claimed in divisional application for Battery assemblies, filed May 24, 1939, Serial No. 275,524.

While Ihave herein shown and described one or more ways .of carrying out the objects of the invention and presenteddiffercnt, forms for producing this result, it will be readily understood that variations, changesor modifications therein may be found desirable-or essential in meeting the various exigencies ofserviceor the individual desires of acustomer, andltherefore desireit to be understood that I;rese rvethe right to make any and all such changes and modifications therein as may be found desirable or, essential insofar as the same may comewithinthe spirit and scope of the invention as expressed in the accompanying claims when broadly construed.

Having thus described my invention, what is.

claimed is:

1. In lighting assemblies and in combination, a portable lighting unit of the flash-light type and wherein the axes of bulb and battery arein substantial alinement, said unit comprising a casing carrying a bulb zone, a rechargeable battery, and manually-controllable connections between the battery and bulb with the connections including the casing; and a support for th unit, said support having connections with a charging circuit of low-rate charging values and with the charging circuit broken'in the absence of the lighting "'t and completed bythe positioning of the u; t on its support; said unit and support having cc-cperative terminal means relatively positioned to be automatically. rendered. active by positioning of the unit on the support with the bulb zone of the lighting unit contacting the supporting face of the support to thereby complete the charging circuit to the battery of the unit, the terminal means for one side of the circuit presenting the zone of contact of the cooperating terminals as internal of the casing, the opposite side of the charging circuit being completed by external contact of the support terminal with the unit casing, whereby the charging circuit to the battery will be automatically completed by positioning the unit on the support with the unit battery in normal position within the unit above the bulb zone, the co-opcrating terminal means for one side of the charging circuit comprising an internal terminal carried by the unit casing and extending into the unit circuit connections between battery and bulb, and a yielding terminal carried by the support and adapted to extend through a casing opening to contact a predetermined zone of the internal terminal, the terminal means for the opposite side of the charging circuit being in the form of a clamp carried by the support and forming part of the charging circuit with the clamp co-operative with the unit casing to complete the charging circuit when the unit is positioned on the support.

2. An assembly as in claim 1 characterised in that the connections to the clamp include a removable resistance element to thereby permit variation of resistance values to control the charging rate.

3. In lighting assemblies and in combination a portable lighting unit of the flash-light type and wherein the axes of bulb and battery are in substantial alinement, said unit comprising a casing carrying a bulb-zone, a rechargeable battery, and manually-controllable connections between the battery and bulb with the connections including the casing; and a support for the unit, said support having connections with a charging circuit of low-rate charging values and with the charging circuit broken in the absence of the lighting unit and completed by the positioning of the unit on its support; said unit and sup-' port having co-operative terminal means relatively positioned to be automatically rendered active by positioning of the unit on the support with the bulb zone of the lighting unit contacting the supporting face of the support to thereby complete the charging circuit to the battery of the unit, the terminal means for one side of the circuit presenting the zone of contact of the cooperating terminals as internal of the casing, the opposite side of the charging circuit being completed by external contact of the support terminal with the unit casing, whereby the charging circuit to the battery will be automatically completed by positioning the unit on the support with the unit battery in normal position within the unit above the bulb zone, the battery terminals being positioned at opposite ends of the battery with the positive terminal remote from the bulb zone, the battery unit including a venting unit having its outlet through the positive terminal of the battery, the cooperating terminal means of support and lighting unit being relatively positioned to permit completion of the charging circuit when the lighting unit is positioned on its support with the positive terminal end of the battery uppermost.

4. In lighting assemblies and in combination, a portable lighting unit of the flash-light type and wherein the axes of bulb and battery are in substantial alinement, said unit comprising a casing carrying a bulb-zone, a rechargeable battery, and manually-controllable connections between the battery and bulb with the connections including the casing; and a support for the unit, said support having connections with a charging circuit of low-rate charging values and with the charging circuit broken in the absence of the lighting unit and completed by the positioning of the unit on its support; said unit and support having co-operative terminal means relatively positioned to be automatically rendered active by positioning of the unit on the support with the bulb zone of the lighting unit contacting the supporting face of the support to thereby complete the charging circuit to the battery of the unit, the terminal means for one side of the circuit presenting the zone of contact of the cooperating terminals as internal of the casing, the opposite side of the charging circuit being completed by external contact of the support terminal with the unit casing, whereby the charging circuit to the battery will be automatically completed by positioning the unit on the support with the unit battery in normal position within the unit above the bulb zone, the support being of general L-shape configuration with the flash-light supporting face presented as the horizontal leg of the support, clips carried by the support and adapted to removably embrace the unit casing at spaced-apart points, said support carrying charging terminals with one of such terminals active on the battery through the contact of a clip and the unit casing, and with the other terminal rendered active with the battery by contact with the unit internal terminal through an opening in the unit casing, both support terminals being rendered active automatically by the positioning of the unit on the support and rendered inactive by the removal of the unit from the support.

BENJAMIN D. EMANUEL. 

